Fan System with Control Cooling and Method

ABSTRACT

A fan assembly and associated methods are disclosed. In one example, the fan assembly includes an electric motor and motor controller with a heat exchanger coupled between the motor controller and an airflow pathway of the fan assembly. In selected examples, a method of operating a fan assembly includes cooling a motor controller that is located external to an airflow pathway by conducting heat from the motor controller into the airflow pathway using a heat exchanger.

CLAIM OF PRIORITY

This application claims the benefit of priority to U.S. Provisional Patent Application Ser. No. 62/819,730, filed on Mar. 18, 2019, which is hereby incorporated by reference herein in its entirety.

TECHNICAL FIELD

Embodiments described herein generally relate to fans having electronic control circuitry and methods.

BACKGROUND

Industrial fans for HVAC, venting, or other uses typically utilize a local electronic module to control one or more motor function. It is desired to provide fan assembly configurations that provide high efficiency and reliability to the assemblies. In one example, specifically improving efficiency and reducing stress on the electronic module is desired. Improved fan assembly configurations and methods are desired that address these concerns, and other technical challenges.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A shows a fan assembly in accordance with some example embodiments.

FIG. 1B shows another fan assembly in accordance with some example embodiments.

FIG. 1C shows another fan assembly in accordance with some example embodiments.

FIG. 2 shows a heat exchanger in accordance with some example embodiments.

FIG. 3 shows a heat exchanger in accordance with some example embodiments.

FIG. 4 shows another fan assembly in accordance with some example embodiments.

FIG. 5 shows a flow diagram of a method of operation of a fan assembly in accordance with some example embodiments.

DESCRIPTION OF EMBODIMENTS

The following description and the drawings sufficiently illustrate specific embodiments to enable those skilled in the art to practice them. Other embodiments may incorporate structural, logical, electrical, process, and other changes. Portions and features of some embodiments may be included in, or substituted for, those of other embodiments. Embodiments set forth in the claims encompass all available equivalents of those claims.

FIG. 1A shows an example fan assembly 100. The fan assembly 100 includes a fan housing 102 that defines an airflow pathway 104. In operation, airflow is indicated by arrows within the airflow pathway 104. Inlet airflow 106 and outlet airflow 108 are both indicated within the airflow pathway 104.

An impeller 110 is further illustrated in FIG. 1A, located within the airflow pathway 104. In the example of FIGS. 1A-1C, an axial flow impeller is shown, although he invention is not so limited. Other impeller types, including, but not limited to, radial flow impellers, or mixed axial and radial flow impellers are also within the scope of the invention.

The impeller 110 is coupled to a shaft 114 of an electric motor 112. FIG. 1A further shows a motor controller 116 that is mounted outside the airflow pathway 104. In one example, the motor is an electronically commutated (EC) motor that is controlled by the motor controller 116. Although an EC motor is used as an example, other electric motors are within the scope of the invention. FIG. 1A shows the motor controller 116 coupled to the electric motor 112 through connecting wires 118. Connecting wires 118 may provide both power and control information to the electric motor 112. In the example shown, the connecting wires 118 are housed within an electrical connection conduit 120.

In one example, the motor controller 116 is located partially or completely outside the airflow pathway 104 to facilitate easier electrical connection to an external power source (not shown). In one example, the motor controller 116 is located partially or completely outside the airflow pathway 104 to reduce bulky circuitry that may impede air flow. In one example, motor controller 116 is located partially or completely outside the airflow pathway 104 to improve access for maintenance or service to the motor controller 116.

FIG. 1A further shows a heat exchanger 122 located at least partially within the airflow pathway 104 and coupled between the airflow pathway 104 and the motor controller 116. In operation, the motor controller 116 may generate significant heat. By providing increased cooling to the motor controller 116, improved efficiency of the motor controller 116 and/or increased output of the controller 116 will be realized. In addition, by removing the motor controller 116 from the airflow pathway 104, the electric motor 112 is in direct contact with a larger portion of the airflow 106, 108. The additional exposure of the electric motor 112 to the airflow 106, 108 provides improved motor cooling, which further improves performance of the fan system 100 as a whole.

In the example of FIG. 1A, the heat exchanger 122 is incorporated at least partially into the electrical connection conduit 120. By incorporating the heat exchanger 122 into existing structures within the airflow pathway 104, a number of obstructions to airflow is reduced.

FIG. 1B shows another example of a fan assembly 130 according to an embodiment of the invention. In FIG. 1B, the heat exchanger 122 is located separately within the airflow pathway 104. In one example, by locating the heat exchanger 122 by itself, apart from other structures within the airflow pathway 104, an amount of surface area of the heat exchanger 122 exposed to airflow is increased, and cooling efficiency will be higher.

FIG. 1C shows another example of a fan assembly 160 according to an embodiment of the invention. In FIG. 1C, the heat exchanger 122 is incorporated into an electric motor support structure 162. Similar to integration of the heat exchanger 122 within the electrical connection conduit 120, the incorporation of the heat exchanger 122 at least partially within the electric motor support structure 162 reduces the number of components within the airflow pathway 104 that may reduce airflow. In the example of FIG. 1C, a lateral heat transfer connection 124 is shown to couple the heat exchanger 122 to the motor controller 116.

FIGS. 1A-1C show the heat exchanger 122 extending towards the electric motor 112 to an intermediate distance. In other examples, the heat exchanger 122 may extend the full distance to the electric motor 112, or to a lesser distance, provided some active portion of the heat exchanger 122 is at least partially within the airflow pathway 104. In operation, the portion of the heat exchanger 122 within the airflow pathway 104 exchanges heat drawn from the electric motor 112 with the airflow 106, 108 to cool the motor controller 116.

In one example, the heat exchanger 122 is located within the inlet airflow 106. In one example, the heat exchanger 122 is located within the outlet airflow 108. In the examples of FIG. 1A-1C, the heat exchanger 122 is located proximate to the motor controller 116 to make the heat transfer path relatively short. Although a single heat exchanger 122 is shown, multiple heat exchangers may be used. In one example, heat exchangers are located in both the inlet airflow 106 and the outlet airflow 108. Multiple heat exchangers may increase a rate of cooling and/or a cooling amount.

FIG. 2 shows one example of a heat exchanger 200 that may be similar to heat exchanger 122 from FIGS. 1A-1C. In the example of FIG. 2, the heat exchanger 200 includes a cooling medium configured to circulate between a motor controller as shown in previous figures, and other active portions of the heat exchanger 200. A channel 210 is shown with arrows 212 indicating flow of a cooling media. In one example, the cooling media includes a liquid. In one example, the cooling media includes a gas. In one example, the cooling media is circulated through the channel 210 with a pump (not shown).

The heat exchanger 200 of FIG. 2 shows a first region 202 and a second region 204, with the channel 210 located to circulate the cooling media between the first region 202 and the second region 204. In one example, the first region 202 is thermally coupled to a motor controller as shown in FIG. 1A-1C. In one example, the second region 204 is located at least partially within an airflow pathway such as airflow pathway 104. An intermediate region 206 may be included separating the first region 202 from the second region 204. In one example, the intermediate region 206 may be located by a fan housing such as fan housing 102.

In one example, one or more of the regions 202, 204, 206 are formed from heat conducting materials, such as metal or metal alloy. Other heat conducting materials may include carbon or carbon fiber composites. In one example, the second region 204 includes one or more fins 220. The inclusion of fins on the second region 204 increases a surface area of the second region 204, and provides increased heat transfer from the second region 204. Fins may be integrally formed into the second region 204, or may be attached in contact with the second region 204 to provide a thermal pathway. In one example, the fins 220 are oriented parallel to an airflow pathway to improve laminar airflow while providing a heat transfer function. In one example, the fins 220 are oriented vertically. Other orientations of fins 220 are also within the scope of the invention. Other surface area increasing features are also within the scope of the invention. For example, dimples or protrusions of any shape may be added to the second region 204 to increase heat transfer ability.

FIG. 3 shows one example of a heat exchanger 300 that may be similar to heat exchanger 122 from FIGS. 1A-1C. In the example of FIG. 3, the heat exchanger 300 does not include an active system such as the circulating cooling media of heat exchanger 200. The example heat exchanger 300 is a passive heat exchanger, wherein heat is conducted through heat conducting materials such as metal, metal alloys, carbon, composites, etc. The heat exchanger 300 shows a first region 302 and a second region 304. Similar to the heat exchanger 200 of FIG. 2, in one example, the first region 302 is thermally coupled to a motor controller as shown in FIG. 1A-1C. In one example, the second region 304 is located at least partially within an airflow pathway such as airflow pathway 104.

In one example heat exchanger 300 includes one or more fins 310 separated from one another by spaces 312, located on the second region 304. Similar to the example of FIG. 2, the inclusion of fins 310 on the second region 304 increases a surface area of the second region 304, and provides increased heat transfer from the second region 304. Fins may be integrally formed, or may be attached in contact with the second region 304. Ion one example, the fins 310 are oriented parallel to an airflow pathway to improve laminar airflow while providing a heat transfer function. Other orientations of fins 310 are also within the scope of the invention. Other surface area increasing features are also within the scope of the invention.

FIG. 4 shows another fan assembly 400 that may incorporate a heat exchanger as described in the above examples. The fan assembly 400 includes a fan housing 402 and an impeller 410. In the example of FIG. 4, the impeller 410 is a centrifugal impeller. A motor 410 and a motor controller 416 are shown coupled to the impeller 410. In one example, the motor controller 416 is located outside of an airflow pathway. In selected examples, the motor 410 may also be located outside the airflow pathway. A heat exchanger 422 is shown in block diagram form coupled to the motor controller 416, and located at least partially within an airflow pathway. For ease of illustration, the airflow pathway is shown without additional walls or other containment to define the airflow pathway. In the example of FIG. 4, the unillustrated containment structure, such as a wall, will be located to separate at least the motor controller 422 from the airflow pathway. The example of FIG. 4, illustrates that a heat exchanger may be coupled between a motor controller and an airflow pathway in a number of different fan types, and that the invention is not limited to axial fan assemblies.

FIG. 5 shows a flow diagram of a method of operating a fan assembly. In operation 502, an electric motor is controlled within an airflow pathway of a fan housing using a motor controller. The motor controller is located outside or at least partially outside the airflow pathway. In operation 504, an impeller is rotated within the airflow pathway, where the impeller is driven by the electric motor. In operation 506, heat is drawn from the motor controller through a heat exchanger coupled to the motor controller, and the heat is transferred to air flowing within the airflow pathway using the heat exchanger.

To better illustrate the fans and methods disclosed herein, a non-limiting list of embodiments is provided here:

Example 1 includes a fan assembly. The fan assembly includes a fan housing, defining an airflow pathway, an impeller located within the airflow pathway of the fan housing, wherein the impeller is coupled to a shaft of an electric motor, a motor controller mounted outside the airflow pathway, the motor controller electrically coupled to the electric motor, and a heat exchanger located at least partially within the airflow pathway, and coupled between the airflow pathway and the motor controller, wherein the heat exchanger is configured to move heat from the motor controller to the airflow pathway when the fan assembly is in operation.

Example 2 includes the fan assembly of example 1, wherein the heat exchanger includes one or more cooling fins.

Example 3 includes the fan assembly of any one of examples 1-2, wherein the heat exchanger includes a cooling medium configured to circulate between the motor controller and the heat exchanger.

Example 4 includes the fan assembly of any one of examples 1-3, wherein the cooling medium includes a liquid cooling medium.

Example 5 includes the fan assembly of any one of examples 1-4, wherein the impeller is an axial flow impeller.

Example 6 includes the fan assembly of any one of examples 1-5, wherein the impeller is a radial flow impeller.

Example 7 includes the fan assembly of any one of examples 1-6, wherein the heat exchanger is incorporated into an electric motor support structure.

Example 8 includes the fan assembly of any one of examples 1-7, wherein the heat exchanger is incorporated into an electrical connection conduit.

Example 9 includes a fan assembly. The fan assembly includes a fan housing, defining an airflow pathway, an electric motor located within the fan housing, an impeller coupled to a shaft of the electric motor, a motor controller mounted outside the airflow pathway, and one or more metal fins located at least partially within the airflow pathway, and physically contacting the motor controller, wherein the one or more metal fins are configured to move heat from the motor controller to the airflow pathway when the fan assembly is in operation.

Example 10 includes the fan assembly of example 9, wherein the impeller is an axial flow impeller.

Example 11 includes the fan assembly of any one of examples 9-10, wherein the impeller is a radial flow impeller.

Example 12 includes the fan assembly of any one of examples 9-11, wherein the one or more metal fins are incorporated into an electric motor support structure.

Example 13 includes the fan assembly of any one of examples 9-12, wherein the one or more metal fins are incorporated into an electrical connection conduit between the electric motor and the motor controller.

Example 14 includes a method of cooling, including controlling an electric motor within an airflow pathway of a fan housing using a motor controller, wherein the motor controller is located outside the airflow pathway, rotating an impeller driven by the electric motor within the airflow pathway, and drawing heat from the motor controller through a heat exchanger coupled to the motor controller, and transferring the heat to air flowing within the airflow pathway using the heat exchanger.

Example 15 includes the method of example 14, wherein drawing heat from the motor controller through a heat exchanger includes transferring heat to a cooling medium and circulating the cooling medium through the airflow pathway.

Example 16 includes the method of any one of examples 14-15, wherein drawing heat from the motor controller through a heat exchanger includes conducting heat from the motor controller into one or more metallic fins, wherein the one or more metallic fins are located within the airflow pathway.

Example 17 includes the method of any one of examples 14-16, wherein rotating the impeller includes rotating an axial impeller.

Example 18 includes the method of any one of examples 14-17, wherein rotating the impeller includes rotating a radial impeller.

Throughout this specification, plural instances may implement components, operations, or structures described as a single instance. Although individual operations of one or more methods are illustrated and described as separate operations, one or more of the individual operations may be performed concurrently, and nothing requires that the operations be performed in the order illustrated. Structures and functionality presented as separate components in example configurations may be implemented as a combined structure or component. Similarly, structures and functionality presented as a single component may be implemented as separate components. These and other variations, modifications, additions, and improvements fall within the scope of the subject matter herein.

Although an overview of the inventive subject matter has been described with reference to specific example embodiments, various modifications and changes may be made to these embodiments without departing from the broader scope of embodiments of the present disclosure. Such embodiments of the inventive subject matter may be referred to herein, individually or collectively, by the term “invention” merely for convenience and without intending to voluntarily limit the scope of this application to any single disclosure or inventive concept if more than one is, in fact, disclosed.

The embodiments illustrated herein are described in sufficient detail to enable those skilled in the art to practice the teachings disclosed. Other embodiments may be used and derived therefrom, such that structural and logical substitutions and changes may be made without departing from the scope of this disclosure. The Detailed Description, therefore, is not to be taken in a limiting sense, and the scope of various embodiments is defined only by the appended claims, along with the full range of equivalents to which such claims are entitled.

As used herein, the term “or” may be construed in either an inclusive or exclusive sense. Moreover, plural instances may be provided for resources, operations, or structures described herein as a single instance. Additionally, boundaries between various resources, operations, modules, engines, and data stores are somewhat arbitrary, and particular operations are illustrated in a context of specific illustrative configurations. Other allocations of functionality are envisioned and may fall within a scope of various embodiments of the present disclosure. In general, structures and functionality presented as separate resources in the example configurations may be implemented as a combined structure or resource. Similarly, structures and functionality presented as a single resource may be implemented as separate resources. These and other variations, modifications, additions, and improvements fall within a scope of embodiments of the present disclosure as represented by the appended claims. The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense.

The foregoing description, for the purpose of explanation, has been described with reference to specific example embodiments. However, the illustrative discussions above are not intended to be exhaustive or to limit the possible example embodiments to the precise forms disclosed. Many modifications and variations are possible in view of the above teachings. The example embodiments were chosen and described in order to best explain the principles involved and their practical applications, to thereby enable others skilled in the art to best utilize the various example embodiments with various modifications as are suited to the particular use contemplated.

It will also be understood that, although the terms “first,” “second,” and so forth may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first contact could be termed a second contact, and, similarly, a second contact could be termed a first contact, without departing from the scope of the present example embodiments. The first contact and the second contact are both contacts, but they are not the same contact.

The terminology used in the description of the example embodiments herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used in the description of the example embodiments and the appended examples, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will also be understood that the term “and/or” as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

As used herein, the term “if” may be construed to mean “when” or “upon” or “in response to determining” or “in response to detecting,” depending on the context. Similarly, the phrase “if it is determined” or “if [a stated condition or event] is detected” may be construed to mean “upon determining” or “in response to determining” or “upon detecting [the stated condition or event]” or “in response to detecting [the stated condition or event],” depending on the context. 

1. A fan assembly, comprising: a fan housing, defining an airflow pathway; an impeller located within the airflow pathway of the fan housing, wherein the impeller is coupled to a shaft of an electric motor; a motor controller mounted outside the airflow pathway, the motor controller electrically coupled to the electric motor; and a heat exchanger located at least partially within the airflow pathway, and coupled between the airflow pathway and the motor controller, wherein the heat exchanger is configured to move heat from the motor controller to the airflow pathway when the fan assembly is in operation.
 2. The fan assembly of claim 1, wherein the heat exchanger includes one or more cooling fins.
 3. The fan assembly of claim 1, wherein the heat exchanger includes a cooling medium configured to circulate between the motor controller and the heat exchanger.
 4. The fan assembly of claim 3, wherein the cooling medium includes a liquid cooling medium.
 5. The fan assembly of claim 1, wherein the impeller is an axial flow impeller.
 6. The fan assembly of claim 1, wherein the impeller is a radial flow impeller.
 7. The fan assembly of claim 1, wherein the heat exchanger is incorporated into an electric motor support structure.
 8. The fan assembly of claim 1, wherein the heat exchanger is incorporated into an electrical connection conduit.
 9. A fan assembly, comprising: a fan housing, defining an airflow pathway; an electric motor located within the fan housing; an impeller coupled to a shaft of the electric motor; a motor controller mounted outside the airflow pathway; and one or more metal fins located at least partially within the airflow pathway, and physically contacting the motor controller, wherein the one or more metal fins are configured to move heat from the motor controller to the airflow pathway when the fan assembly is in operation.
 10. The fan assembly of claim 9, wherein the impeller is an axial flow impeller.
 11. The fan assembly of claim 9, wherein the impeller is a radial flow impeller.
 12. The fan assembly of claim 9, wherein the one or more metal fins are incorporated into an electric motor support structure.
 13. The fan assembly of claim 9, wherein the one or more metal fins are incorporated into an electrical connection conduit between the electric motor and the motor controller.
 14. A method of cooling comprising: controlling an electric motor within an airflow pathway of a fan housing using a motor controller, wherein the motor controller is located outside the airflow pathway; rotating an impeller driven by the electric motor within the airflow pathway; and drawing heat from the motor controller through a heat exchanger coupled to the motor controller, and transferring the heat to air flowing within the airflow pathway using the heat exchanger.
 15. The method of claim 14, wherein drawing heat from the motor controller through a heat exchanger includes transferring heat to a cooling medium and circulating the cooling medium through the airflow pathway.
 16. The method of claim 14, wherein drawing heat from the motor controller through a heat exchanger includes conducting heat from the motor controller into one or more metallic fins, wherein the one or more metallic fins are located within the airflow pathway.
 17. The method of claim 14, wherein rotating the impeller includes rotating an axial impeller.
 18. The method of claim 14, wherein rotating the impeller includes rotating a radial impeller. 